FOOTWEAR ITEMS HAVING LIGHT INTERMEDIATE SOLE MEMBERS WITH PROTECTIVE ELEMENTS

专利摘要:
sole structures and footwear articles having lightweight midsole members with protective elements. structures and soles for footwear, including athletic footwear, include a relatively soft and lightweight foam midsole component partially covered by at least one more rigid and/or denser box (protector) component(s) and/or another component. (s) protector.
公开号:BR112015022556B1
申请号:R112015022556-0
申请日:2014-03-14
公开日:2021-06-15
发明作者:Frederick J. Dojan；Matthew J. Holmes；Troy C. Lindner；Benjamin Nethongkome；Dolores S. Thompson
申请人:Nike Innovate C.V.；
IPC主号:

专利说明:

Related Order Data
[001] This application claims priority for: (a) US Patent Application no. 13/835,715 entitled “Sole Structures and Articles of Footwear Having a Lightweight Midsole Member with Protective Elements” and filed March 15, 2013; (b) US Patent Application no. 13/838,051, entitled "Sole Structures and Articles of Footwear Having a Lightweight Midsole Member with Protective Elements" and filed March 15, 2013, and (c) US Patent Application no. 13/837,967 entitled "Sole Structures and Articles of Footwear Having a Lightweight Midsole Member with Protective Elements" and filed March 15, 2013. Each such priority request is incorporated herein by reference in its entirety. Field of Invention
[002] The present invention relates to the field of footwear. More specifically, aspects of the present invention pertain to sole structures and/or articles of footwear (e.g., athletic footwear) that include a relatively soft and/or lightweight foam midsole component partially covered by the protective components. Background
[003] Conventional articles of athletic footwear include two primary elements, namely, an upper and a sole structure. The upper provides a foot cover that securely receives and positions the foot in relation to the sole frame. In addition, the upper may have a configuration that protects the foot and provides ventilation, thus cooling the foot and removing perspiration. The sole frame is attached to a lower surface of the upper and is usually positioned between the foot and any contact surface. In addition to attenuating ground reaction forces and energy absorption, the sole structure can provide traction and control of potentially harmful foot movement, such as over-pronation. The general characteristics and configurations of the upper and sole structure are discussed in more detail below.
[004] The upper part forms an empty space inside the article of footwear to receive the foot. The empty space is the general shape of the foot, and access to the empty space is provided through an opening in the ankle. Thus, the top extends over the instep and toe areas, along the middle sides and sides of the foot, and around the heel area. A lace system is often incorporated into the upper to selectively change the size of the ankle opening and to allow the user to modify certain dimensions of the upper, particularly perimeter, to accommodate feet of varying proportions. In addition, the upper may include a tongue that extends under the lace system to improve the comfort of the shoe (eg, for moderate pressure applied to the foot by the laces), and the upper may also include an anti-heel for limit or control heel movement.
[005] The sole structure generally incorporates several layers that are conveniently referred to as an "insole", a "middle sole," and an "outsole." The insole (which can also form a sock lining) is a thin member located inside the upper and adjacent to the plantar (bottom) surface of the foot to improve the comfort of the shoe, eg, to wick away moisture and provide a feel soft and comfortable. The midsole, which is traditionally attached to the upper along the entire length of the upper, forms a middle layer of the sole structure and serves a variety of purposes including controlling foot movement and mitigating impact forces. The outsole forms the ground contact element of the shoe and is generally formed from a durable, wear-resistant material that includes textures or other features to improve traction.
[006] The primary element of a conventional midsole is a resilient, polymeric foam material such as polyurethane foam or ethyl vinyl acetate ("EVA") foam, which extends over the entire length of the shoe. The properties of the polymer foam material in the midsole are essentially dependent on factors including the dimensional configuration of the midsole and the specific characteristics of the material selected for the polymer foam, including the density and/or hardness of the polymer foam material. . By varying these factors throughout the midsole, the relative stiffness, degree of attenuation of the ground reaction force, and energy absorption properties can be altered to meet the specific demands of the activity for which the footwear is intended to be used. .
[007] Despite the numerous available shoe designs and features, new shoe designs and constructions continue to develop and are a welcome advancement in the technique. Invention Summary
[008] This summary is provided to introduce some general concepts related to the present invention in a simplified form which are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the invention.
[009] While potentially useful for any desired types or styles of shoes, aspects of this invention may be of particular interest to sole structures used in athletic footwear articles, including basketball shoes, running shoes, miscellaneous training shoes, athletic shoes. locks, sneakers, golf shoes, etc.
[010] More specific aspects of this invention refer to sole structures for footwear articles that include a first member of polymeric foam to support at least one heel and middle foot area of a user's foot. An exposed outer edge of this first polymeric foam member includes a corrugated structure that, at least in some examples, extends from an area of the midfoot and toe of the first polymeric foam member, around the area. from the rear heel, and to a midfoot or lateral toe area of the first polymeric foam member. Other corrugated structures, e.g., including braided waves, support ribs, etc., can be provided in at least some examples of this invention. These wave structures may include two to eight outer wave grooves connected by interstitial wave areas located between outer wave grooves of the adjacent wave.
[011] Sole structures according to other examples of this invention may include a polymeric foam member (optionally a lightweight, low density polymeric foam material such as a foam material having a density less than 0.25 g/ cm3) to support at least one heel and middle foot area of a user's foot. An exposed outer edge of this polymeric foam member may include: (a) a first corrugated structure which includes: a first outer wave groove, a second outer wave groove, a third outer wave groove, a first interstitial region located between the first and second outer wave groove, and a second interstitial region located between the second and third outer wave grooves, and(b) a second wave structure including: a fourth outer wave groove, a fifth outer wave groove, and a third interstitial region located between the fourth and fifth outer wave sulcus, with the fourth outer wave groove originating in the first interstitial region and the fifth outer wave groove originating in the second interstitial region. The exposed outer edge of the polymeric foam member may include yet another corrugated structure, e.g., an outer corrugated groove of that corrugated structure originating in the third interstitial region. One corrugated frame may extend around the back heel area of the sole frame, while another may be located in a mid-foot region of the side frame of the sole frame. An outsole component may be coupled with a bottom surface of the polymeric foam member.
[012] Another sole structure according to some examples of this invention includes: a first polymeric foam member to support at least one heel area of a user's foot, the first polymeric foam member being an outer structure having: (a) a sidewall, (b) a middle sidewall, (c) a back heel wall connecting the middle sidewall and the sidewall, (d) a bottom wall connecting the middle sidewall, the sidewall , and the rear heel wall, and (e) an open end opposite the rear heel wall, and this first polymeric foam member extends around the rear heel area of the sole frame. A second polymeric foam member has a heel portion at least partially received in a space defined by the outer structure of the first polymeric foam member, with a toe end of the second polymeric foam member extending beyond the open end of the first polymeric foam member. This second polymeric foam member has a density that is less than the density of the first polymeric foam member, and a portion of a lower surface of the second polymeric foam member is exposed in an area of the lower toe of the article of footwear. If desired, one or more protective elements may be engaged with the lower surface of the second polymeric foam member in the lower toe area.
[013] Yet another sole structure in accordance with some examples of this invention will include: (a) a polymeric foam member to support an entire plantar surface of a user's foot, the polymeric foam member including a foam material that has a density less than 0.25 g/cm3, and (b) a protective member engaged with the polymeric foam member to cover at least 80% of a surface area of a lower surface of the polymeric foam member, wherein the protective member constitutes a weft base surface with a plurality of traction elements extending downwardly from the weft base surface, and being a thickness of a majority of the weft base surface at locations between the plurality of traction elements it is less than 2mm thick.
[014] Additional aspects of this invention refer to articles of footwear including sole structures of various types described above coupled to an upper. Still further aspects of this invention relate to methods for making the sole structures and/or articles of footwear of various types described above (and described in more detail below). More specific aspects of this invention will be described in more detail below. Brief Description of Drawings
[015] The foregoing Summary of the Invention, as well as the following Detailed Description of the Invention, will be better understood when considered in conjunction with the accompanying drawings, in which like reference numerals refer to the same or similar elements throughout the various views in that reference number appears.
[016] Figs. 1A-1F illustrate a sole structure according to an example of this invention;
[017] Figs. 2A-2F illustrate a sole structure in accordance with another example of this invention;
[018] Figs. 3A and 3B illustrate features of a sole structure according to another example of this invention;
[019] Fig. 4 illustrates a heel area of a portion of a foam component that can be included in the sole structures according to some examples of this invention;
[020] Fig. 5 illustrates a basketball shoe according to an example of this invention;
[021] Fig. 6 illustrates a running shoe according to an example of this invention;
[022] Fig. 7 illustrates a training shoe according to an example of this invention;
[023] Figs. 8A-8F illustrate a sole structure in accordance with another example of this invention;
[024] Fig. 9 is an enlarged view of a sole structure according to another example of this invention;
[025] Figs. 10A and 10B illustrate features of a sole structure in accordance with another example of this invention;
[026] Figs. 11A-11C provide several views of an article of footwear in accordance with another example of this invention; and
[027] Figs. 12A-12C provide several views of an article of footwear in accordance with another example of this invention. Detailed Description of the Invention
[028] In the following description of several examples of shoe structures and components according to the present invention, reference is made to the accompanying drawings, which are part of the same, and in which several exemplary structures and environments in which aspects of the invention can be practiced. It should be understood that other structures and environments can be used and that structural and functional modifications can be made from the structures and functions specifically described, without departing from the scope of the present invention.I. Overview of Aspects of this Invention
[029] Some aspects of this invention pertain to sole structures and/or footwear articles (eg, athletic footwear) that include a relatively soft and lightweight midsole foam component partially covered by at least one component(s) of more rigid and/or dense box (protector) and/or other protective components. More specific features and aspects of this invention will be described in more detail below.A. Resources of sole structures and articles of footwear according to the Examples of this Invention
[030] Some aspects of this invention relate to sole structures for footwear articles and footwear articles (or other foot receiving devices), including athletic footwear, having such sole structures. Sole structures for footwear articles in accordance with at least some examples of this invention may include a first polymeric foam member to support at least one heel and midfoot area of a wearer's foot. An exposed outer edge of this first polymeric foam member includes a corrugated structure that extends from an area of the midfoot and toe of the first polymeric foam member, around the rear heel area, to an area. the midfoot or lateral toe of the first polymeric foam member. This wave structure may include two to eight outer wave grooves connected by interstitial wave areas located between outer wave grooves of the adjacent wave.
[031] Sole structures according to at least some examples of this invention may include outsole components (eg, made of rubber, nylon, phyllite, thermoplastic polyurethane, or the like) on the undersurface(s) of one or more of the protective foam components and/or the foam midsole component (eg, in one of the exposed spaces). The outsole component(s) can provide, for example, hardness, strength, wear resistance and traction (eg, by providing texture, cleats, or other structures that increase traction on the underside of the sole frame). In some exemplary structures in accordance with this invention, several independent outsole components will be provided at several discrete locations around the underside of the outsole structure. Outsole components can also be considered a “protective” component for the lightweight midsole component.
[032] If desired, in accordance with at least some examples of this invention, at least some portions of the outer side edges of one or more of the lighter and/or less dense foam midsole material components and/or a protective component denser (optionally made of a heavier or denser polymeric foam material), may include a corrugated structure (described in more detail below). Additionally or alternatively, if desired, at least some portions of the foam midsole component may include the corrugated structure, e.g., optionally adjacent to the corrugated structure of the one or more protective components (if they are corrugated). While any number of individual corrugated structures is possible in the various components without departing from this invention, in some examples, in a top-down direction, an individual sole structure may include from 2 to 8 waves, and in some examples, from 3- 6 waves.
[033] Sole structures according to other examples of this invention may include a polymeric foam member (optionally a lightweight, low density polymeric foam material such as a foam material having a density less than 0.25 g/cm3 ) to support at least one heel and midfoot area of a user's foot. An exposed outer edge of this polymeric foam member may include: a first corrugated structure that includes: a first outer wave groove, a second outer wave groove, a third outer wave groove, a first interstitial region located between the first and second outer wave groove, and a second interstitial region located between the second and third outer wave grooves, and a second wavy structure including: a fourth outer wave groove, a fifth outer wave groove, and a third interstitial region located between the external fourth and fifth wave sulcus, with the fourth external wave sulcus originating in the first interstitial region and the fifth external wave sulcus originating in the second interstitial region. The exposed outer edge of the polymeric foam member may include yet another corrugated structure, e.g., an outer corrugated groove of that corrugated structure originating in the third interstitial region. One corrugated frame may extend around the back heel area of the sole frame, while another may be located in a mid-foot region of the side frame of the sole frame. An outsole component may be coupled with a bottom surface of the polymeric foam member.
[034] Another exemplary sole structure according to some examples of this invention includes: a first polymeric foam member to support at least the heel area of a user's foot, the first polymeric foam member constituting an outer structure having : (a) a sidewall, (b) a middle sidewall, (c) a back heel wall connecting the middle sidewall and a sidewall, (d) a bottom wall connecting the middle sidewall, a wall side, and a rear heel wall, and (e) an open end opposite the rear heel wall, and this first polymeric foam member extends around the rear heel area of the sole frame. A second polymeric foam member has a heel portion at least partially received in a space defined by the outer structure of the first polymeric foam member, with a toe end of the second polymeric foam member extending beyond the open end of the first polymeric foam member. This second polymeric foam member has a density that is less than the density of the first polymeric foam member, and a portion of a lower surface of the second polymeric foam member is exposed in an area of the lower toe of the article of footwear. If desired, a protective element may be engaged with the lower surface of the second polymeric foam member in the lower toe area.
[035] Yet another sole structure in accordance with some examples of this invention will include: (a) a polymeric foam member to support an entire plantar surface of a wearer's foot, the polymeric foam member including a foam material that has a density less than 0.25 g/cm3, and (b) a protective member engaged with the polymeric foam member to cover at least 80% of a surface area of a lower surface of the polymeric foam member, wherein the protective member constitutes a weft base surface with a plurality of traction elements extending downwardly from the weft base surface, a thickness of a majority of the weft base surface at locations between the plurality of traction elements being less than 2mm thick.
[036] Still further aspects of this invention relate to footwear articles including uppers (e.g., of any desired design, construction or structure, including conventional designs, constructions or structures) coupled with the sole structures of various types described above (and described in more detail below).
[037] Additional aspects of this invention relate to methods of making articles of footwear or various components thereof. A more specific aspect of this invention relates to the methods for making sole structures for footwear articles of various types and constructions described above. While the various components and pieces of sole structures and footwear articles in accordance with aspects of this invention may be made in ways that are conventionally known and used in the art, examples of the method aspects of this invention relate to the combination of the structure of the sole and/or shoe parts and coupling them together in ways that produce the various structures described above.
[038] Given the general description of the features, aspects, structures, and arrangements in accordance with the invention provided above, a More Detailed Description of the sole structures, articles of footwear, and specific exemplary methods in accordance with this invention follows.II. Detailed Description of Exemplary Sole Structures and Articles of Footwear in accordance with this invention
[039] With reference to the figures and discussion below, various sole structures, articles of footwear, and features thereof in accordance with the present invention are disclosed. The sole and footwear structures illustrated and discussed are athletic shoes, and the concepts disclosed in relation to the various aspects of these footwear can be applied to a wide range of athletic footwear styles, including, but not limited to: walking shoes, sneakers , football shoes, football shoes, basketball shoes, running shoes, diversified training shoes, cleat shoes, golf shoes, etc. In addition, at least some concepts and aspects of the present invention can be applied to a wide range of non-athletic footwear, including work boots, sandals, moccasins and dress shoes. Thus, the present invention is not limited to the precise embodiments disclosed herein, but applies to footwear generally.
[040] Figs. 1A through 1F illustrate several views of an exemplary sole structure 100 for an article of footwear that includes at least some aspects and features of this invention. For the purposes of this disclosure, and as shown in Fig. 1A, portions of an article of footwear (and the various component parts thereof) may be identified based on the regions of the foot located on or near that portion of the article of footwear when the footwear is worn in foot size appropriately. For example, as shown in Fig. 1A, an article of footwear and/or a sole structure can be considered to have a "toe region" in the front of the foot, a "midfoot" region in the middle, or arch area of the foot, and a “heel region” on the back of the foot. Footwear and/or sole structures also include a “lateral side” (the “outer” or “little toe side” of the foot) and a “middle side” (the “inner” or “big side” of the foot. ). The toe region usually includes portions of the shoe corresponding to the toes and the joints that connect the metatarsals with the phalanges. The midfoot region usually includes portions of the shoe corresponding to the arch area of the foot. The heel region usually corresponds with the back portions of the foot, including a calcaneus bone. The lateral and middle sides of the shoe extend through the forefoot, midfoot and heel regions and generally correspond to opposite sides of the shoe (and can be considered to be separated by a central longitudinal axis). These regions (although separated by division lines in Fig. 1A) and sides are not intended to demarcate precise areas of the shoe. Rather, the terms “toe region,” “midfoot region,” “heel region,” “lateral side,” and “middle side” are intended to represent general areas of an article of footwear and the various components of it to aid in the following discussion.
[041] Fig. 1A shows a top view of the structure of the sole 100, Fig. 1B shows a side side view, Fig. 1C shows a middle side view, Fig. 1D shows a bottom view, Fig. 1E shows a view of the heel or back, and Fig. 1F shows a view of the toe side and front. As shown in Figs. 1A to 1F, this exemplary sole structure 100 includes a single midsole component 102 that extends continuously in this particular structure 100 to support a full plantar surface of a wearer's foot, ie, from the back heel area of the sole 100 to the toe area of the sole 100 and from the edge of the side side to the edge of the middle side of the sole 100. While other midsole constructions are possible, according to some examples of this invention, the midsole component 102 it can be a foam material (such as ethyl vinylacetate (“EVA”) foam, polyurethane foam, phylon foam, and the like). The upper surface 102a of the midsole member 102 may be contoured, e.g., to comfortably support and/or help position a plantar surface of a wearer's foot.
[042] In some examples of this invention, the midsole component 102 will be at least partially made of a foam material that has a density of less than 0.25 g/cm3 (and in some examples, a density of less than 0, 2 g/cm3, within the range of 0.075 to 0.2 g/cm3, and further within the range of 0.1 to 0.18 g/cm3). If desired, the foam material of midsole component 102 may include one or more apertures defined therein and/or another impact force attenuating component included therewith, such as a liquid filled bladder, a mechanical shock absorbing member. , etc. In certain embodiments of this invention, the entire midsole component 102 will constitute this lightweight foam material (eg, with a density feature as described above) and will extend to support the wearer's full foot (eg, the full plantar surface ). In the exemplary structure 100 as illustrated in Figs. 1A to 1F, the foam midsole component 102 is shown as a separate part of a protective component 104 (eg, one or more of: another denser or harder midsole material (eg, polymeric foam material) ); an outsole material; a "box" or "carrying member; etc.) by splice line 106 (this splice line 106 is provided as an illustrative aid in the drawings to highlight the change in locations between materials 102/ 104 in these figures). In this illustrated example, midsole component 102 generally sits above protective component 104 (and may be at least partially contained by protective component 104). As other options, the midsole component 102 can be made of multiple pieces of the midsole component (e.g., foam), if desired, and/or the structure of the outsole 100 can include multiple pieces of the protective component 104.
[043] As some even more specific examples, at least some of the midsole 102 components can be made of a foam material as described, for example, in the US Patent. No. 7,941,938, which patent is fully incorporated herein by reference. In at least some exemplary sole structures 100 in accordance with this invention, all, substantially all, or at least some portions of the intermediate sole component 102 may include a foam material comprising a reaction product of about 10 to about 100 parts per hundred of hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, 0 to about 40 parts per hundred of modified hydrogenated acrylonitrile butadiene copolymer, and 0 to about 90 parts per hundred of alpha olefin copolymer, and at least an additive in an adequate amount to form the foam material. This foam material can have a light spongy feel. The density of the foam material can generally be less than 0.25 g/cm3, less than 0.20 g/cm3, less than 18 g/cm3, less than 0.15 g/cm3, less than 0.12 g/ cm3, and in some examples, about 0.10 g/cm3. As exemplary ranges, the density of lightweight foam can fall within the range, for example, from 0.05 to 0.25 g/cm3 or within the various ranges noted above.
[044] Also, according to at least some examples of this invention, the resilience of the foam material for the midsole component 102 may be greater than 40%, greater than 45%, at least 50%, and in an aspect of 50-70%. The compression set can be 60% or less, 50% or less, 45% or less, and in some cases within the 20 to 60% range. The hardness (Asker C Durometer) of the foam material for this exemplary 102 midsole component can be, for example, 25 to 50, 25 to 45, 25 to 35, or 35 to 45, eg, depending on the type of footwear . The tensile strength of the foam material 102 can be at least 15 kg/cm2, and typically 15 to 40 kg/cm2. The % elongation is 150 to 500, typically over 250. The tear strength is 6-15 kg/cm, typically over 7. In at least some exemplary constructions according to the invention, the foam material is at least some portion of the midsole component 102 may have less energy loss and may be lighter than traditional EVA foams. Energy loss can be less than 30%, and optionally within the range of about 20% to about 30%. As additional examples, if desired, at least some portions of the midsole component 102 can be made from foam materials used in the LUNAR family of footwear products available from NIKE, Inc. of Beaverton, Oregon.
[045] While the above paragraphs describe potential properties and features of foam materials for midsole components 102 in accordance with some examples of this invention, those skilled in the art will recognize that the midsole component 102 may have other properties, features and/ or combinations of features desired without departing from this invention. Other lightweight and/or low density foams can also be used. Because of the protective components 104 described in more detail below, the lightweight foam midsole component 102 need not necessarily have sufficient hardness, durability, and/or abrasion resistance to directly contact the soil in use (at least not in some locations of contact with the soil of greater impact).
[046] The protective component 104 in this exemplary sole structure 100 can be made of any desired materials without departing from the invention. For example, the protective component 104 can be made of conventional outsole material such as rubber, thermoplastic polyurethane (TPU), or the like. As another example, protective component 104 may be made, at least in part, from a polymeric foam housing or carrier material such as those described in US Patent. No. 7,941,938 identified above. Other conventional polymer foam materials can also be used for protective component 104.
[047] The foam midsole component 102 and the protective component 104 can be hooked together in any desired way without departing from the invention, including in conventional ways as are known and used in the art (e.g., through cements or adhesives, through mechanical connectors, etc.). In this illustrated example, the protective component 104 fits within one or more recesses formed in the lower and/or side surfaces of the polymeric foam component 102. The recess(s), where present, may be formed during the molding process (or another forming process) in which the lightweight foam component 102 is formed. Alternatively, the recesses can be produced after the lightweight foam component 102 is formed, e.g., by a cutting or grinding action. Protective component 104 may include traction elements or other features to engage the ground or other contact surface in use, such as zigzag structures, raised ribs or protrusions, recessed grooves, etc., including conventional traction elements as are known and used in technique. As further examples, the lower surface of protective member 104 may be formed to include receptacles for receiving removable latches and/or may be formed to include actual latch elements extending from the lower surface thereof.
[048] As further illustrated in Fig. 1D, the lower surface of the protective member 104 need not completely cover the lower surface of the midsole member 102. Instead, some spaces or holes may be provided in the protective member 104 through which the lower surface of the 102 lightweight foam material is exposed. This feature can provide several potential advantages. For example, the elimination of some of the protective components 104 can reduce the weight of the sole structure 100. Additionally, as illustrated in Fig. 1D, breaks or gaps in the protective component 104 can be provided along desired lines of component flexion. protector 104 (eg notches or elongated gaps in the toe area as shown in Fig. 1D), thus helping to maintain the full flexibility (and optionally more natural flexibility) of the overall sole structure 100. The large opening the protective component 104 in the heel area of this exemplary sole structure 100 provides a relatively large and soft "drop pad" for the heel, eg to provide better comfort and feel as the wearer's heel hits the ground, eg, when landing a step or jump. A person skilled in the art, given the benefit of this disclosure, will understand that the openings in the protective component 104 are optional, and, where present, they can be provided in any desired sizes, shapes and/or numbers, without departing from the invention. Preferably, however, the high wear areas on the underside surface of the sole structure 100 will include some layer of a protective component 104 that overlays the lightweight (and more fragile) polymeric midsole component 102, to help protect structural integrity. of the midsole component 102.
[049] As best shown in Figs. 1C and 1D, this exemplary sole structure 100 includes an additional element, i.e., support plate 108 provided in the central or mid-foot area of the sole frame 100. This support plate 108, provides additional support for the area of arch of this sole structure 100. In Figs. 1C and 1D, support plate 108 is shown separated from midsole member 102 and/or protective member 104 by splice line 110. This splice line 110 is provided as an illustrative aid in the drawings to highlight the change in locations. between support plate 108 and materials 102/104 in these figures. In this illustrated example, support plate 108 may be at least partially sandwiched or layered between midsole member 102 and protective member 104 at least in the arch area of sole frame 100. Support plate 108 may be engaged with one or more of midsole component 102 and/or protective component 104 by adhesives or cements, by mechanical connectors, and/or in any other desired manner, including conventional ways known or used in the art. The support plate 108 can be made from any desired number of pieces or parts and/or from any desired materials without departing from the invention, including conventional bow support materials and/or parts as are known and used in the art. Some more specific examples of the materials include: thermoplastic polyurethanes, nylon-based polymer materials (eg, PEBAX), carbon fiber reinforced polymeric materials, glass fiber reinforced polymeric materials, other composite materials, and the like.
[050] Figs. 1A to 1F show another feature that may be included in the sole structures 100 in accordance with at least some examples of this invention. As shown in these figures, at least some portions of the outer edges or sides of the foam midsole component 102 and/or the protective component 104 may include the "ripple structure" 120. The terms "ripple structure" or "wave structure" , as used herein, mean that the shape of the outer surface of the element is the shape of the outer surface of a wave, eg, a wave-like structure with a series of wave peaks (the outermost portion or protrusion) and valleys between the peaks of the wave. In a sole structure, the “ripple structure” does not need to expand and compress in the same way as a conventional wave, but rather the term refers more generally to the shape of the outer surface of the structure. In the illustrated exemplary outsole structure 100, the lightweight foam midsole component 102 has a series of 4% waves 122 (eg, appearing as four disks stacked around the back heel area), and the protective component 104 includes % wave 124 (which joins with the bottom of the wave 122 of the foam midsole component 102 to complete the lowest wave in this structure of the sole 100). At least some portions of the corrugated structure 120 may be provided in the side walls of the midsole component 102 (and its corrugated structure 120) which are raised from the upper surface 102a of the midsole component 102, e.g., so that the midsole component 102 at least partially wraps around the wearer's foot (eg, at least in the heel area). As more specific examples, the outer structure of the midsole component 102 (with the corrugated structure 120 formed therein) may include a sidewall 130, a middle sidewall 132, a rear heel wall 134 connecting the middle sidewall 132, and the sidewall 130, and the upper plantar support surface 102a connecting the middle sidewall 132, the sidewall 130, and the rear heel wall 134. The upper plantar support surface 102a may constitute a layer of polymeric foam (optionally with one or more fluid-filled bladders contained therein) extending downwardly from the upper surface 102a, for example, by about 10-20 mm in the central heel area and/or by about 8-16 mm in the area of the toe (eg, metatarsal head support). Walls 130, 132, and 134 can extend upwards from the top surface 102a and can be tapered or variable in height, eg, from 0-5 mm in the toe area to 25-50 mm (or even more) in the back heel area. At least some portions of the 4% waves of corrugated structure 120 may extend continuously around an outer surface of sidewall 130, rear heel wall 134, and middle sidewall 132.
[051] The size, number, shape and/or other features of the corrugated structure 120 can be selected to control the feel of the footwear article. Typically, a deeper wave (i.e., a larger dimension from a wave crest to the bottom of an adjacent gutter) will provide a more responsive feel (ie, faster return to original shape). The size, density, and/or hardness of the midsole component(s) 102 and/or the protective component(s) 104 may also be controlled to provide control over the feel of the sole structure 100 to a user's foot. The corrugated structure 120 of this illustrated exemplary sole structure 100 extends continuously and uninterruptedly from an area of midfoot or toe of midsole component 102 (see Fig. 1C) to an area of midfoot or side toe of midsole component 102 (see Fig. 1D). This general specific wave structure 120 includes five outer wave protrusions connected by the four interstitial wave areas located between outer wave grooves adjacent to the five outer wave protrusions.
[052] Corrugated structures can take a variety of shapes without departing from this invention. For example, Figs. 1B, 1C, 1E, and 1F show that the walls of the individual waves have a "stepped" configuration and the outermost protrusion of each individual wave constitutes a relatively sharp corner. These are not requirements. As additional examples, if desired, the sidewalls of waves can be smooth, straight, and/or curved. Additionally, the outermost edge or overhang of each wave can be made as a less sharp corner, gently curved, boxed out etc., without departing from the invention. Also, while the corrugated structures may appear similar on the opposite inner side of walls 130, 132, and 134 (eg, with the “cut” wave peaks; eg, see Fig. 9), in this illustrated example, the inner surfaces of the walls 130, 132, and 134 are smooth (ie, these waves are solid and not hollow).
[053] Also, in this illustrated exemplary sole structure 100, in the rear heel area of the midsole component 102, an outer crest of the highest wave (the highest wave crest) is vertically separated from an outer crest of the lower wave (bottom) for a vertical distance of at least 1.5 inches when the sole frame 100 is oriented on a horizontal surface. Additionally or alternatively, in this sole structure 100, in the rear heel area of the midsole component 102, an outer crest of the center wave (the third wave in this example) extends rearward a greater distance when the sole structure 100 is oriented on the horizontal surface. These features can best be seen, for example, in Figs. 1B and 1C.
[054] Also, as best shown in Figs. 1B, 1C, and 1F, an exposed outer edge of the protective component 104 of this exemplary outsole structure 100 includes a corrugated structure 140 that extends around a front toe area of the outsole structure 100. This exemplary corrugated structure 140 includes three outer wave protrusions connected by the two interstitial wave areas located between outer wave grooves adjacent to three outer wave protrusions. As shown, the corrugated structure 140 of the protective component 104 of this exemplary sole structure 100 is not continuous with the corrugated structure 120 of the midsole component 102. Instead, the corrugated structure 140 of the protective component 104 is separate from the corrugated structure 120 of the midsole component 102 by transition areas 142, 144 provided in the lateral toe area and a mid toe area, respectively, of the sole frame 100. Transition areas 142 and/or 144 can be made of the midsole component 102, the protective component 104, and/or other sole component. Also, transition areas 142 and/or 144 can have any desired structure, including another corrugated structure, one or more raised ribs or other support members, etc.
[055] The structure of the sole 100 shown in Figs. 1A to 1F has a wave configuration 120 in which at least some of the individual waves 122, 124 extend continuously and uninterruptedly around the midsole component(s) 102 and/or the protective component(s) 104 from its side-side end to its middle-side end. This is not a requirement. Instead, Figs 2A to 2F show a similar outsole structure 200, having similar parts and construction to the outsole structure 100 of Figs. 1A to 1F, but with a different waveform configuration.
[056] For the sake of brevity, the similar parts between Figs 1A - 1F and those in Figs. 2A - 2F will not be described in detail in this specification. Instead, the following discussion will focus on the differences between the structures shown in Figs. 2A - 2F compared to those shown in Figs. 1A - 1F. As those skilled in the art can understand, parts not described in detail below with respect to Figs. 2A - 2F may have the same or similar structures and/or the same or similar features and/or options for those similar parts and structures described above with respect to Figs. 1A - 1F.
[057] Unlike the 120 wave configuration shown in Figs. 1A - 1F, in which at least some of the individual waves 122, 124 extend continuously and uninterruptedly around the midsole component(s) 102 and/or the protective component(s) 104 from its lateral side end its middle side end, the wave configuration 220 of Figs. 2A - 2F includes interleaved and interlaced waves. As best seen from Figs. 2B, 2C, and 2E, the wave pattern 220a in the back heel area of this sole frame 200 has a wave construction similar to that in the back heel area of the wave pattern 120 in the back heel area of the sole frame 100 of the Figs. 1A - 1F (eg, with five outer wave protrusions and four interstitial wave areas). However, as also best seen from Figs. 2B, 2C, and 2E, the wave configuration 220 in this exemplary sole structure 200 has a different configuration that extends along and forward from the lateral heel and mid-heel areas. More specifically, as illustrated in Fig. 2B, a new series of waves 220b originates in the heel area within the interstitial areas 250 provided between the top three waves of the rear wave configuration 220a. The origins of the new waves in the new wave series 220b are shown in Fig. 2B at points 252 in the interstitial areas 250. From their origin points 252, the three interstitial waves taper to greater widths and heights to form the outermost wave crests to either side of its outermost points 254. Also, the interstitial waves in the new wave series 220b taper to a sufficiently large size so as to completely bypass the rear heel wave series 220a (note , for example, that the back heel waves 220a have origin points 220f at locations within the interstitial areas in the new wave series 220b). Additionally, while not a requirement, in the exemplary sole 200 structure shown in Fig. 2B, the outer crests 254 in the new wave series 220b taper down in size that moves forward from their peak areas to points of end 256. Other support structures, including another wave series configuration as shown in Fig. 2B, may originate from the interstitial areas between the new wave configuration 220b and/or from the outside in the new wave configuration 220b (eg, from points 258) and move forward in the sole frame 200. Then, at least on the side of the heel side shown in Fig. 2B, the new wave series 220b may constitute a central wave configuration with a back wave configuration that extends towards the heel (from origin points 220f) and a forward wave configuration that extends to the midfoot area (from origin points 258).
[058] On the middle side of this sole structure 200, as illustrated in Fig. 2C, another new series of waves 220c originates in the heel area within the interstitial areas 250 provided between the upper three waves of the rear wave configuration 220a. The origins of the new waves in the new wave series 220c are shown in Fig. 2C at points 260 in the interstitial areas 250. From their origin points 260, the three interstitial waves taper to greater widths and heights so as to completely bypass the series of back heel waves 220a (note, for example, that the back heel waves 220a have origin points 220f at locations within the interstitial area in the new series of waves 220c).
[059] The exemplary wave configuration of Figs. 2A - 2F shows different constructions of interstitial waves on the midside v. the side side. This is not a requirement. Instead, if desired, the wave configuration like that of Fig. 2B can be provided on the middle side and/or the wave configuration like that of Fig. 2C can be provided on the side side, without departing from the invention.
[060] Fig. 2D further shows that this sole structure 200 has a slightly different shaped lower surface on the protective component 204 compared to the lower surface of the protective component 104 of the sole structure 100 (shown in Fig. 1D) . This leads to a different pattern of the exposed midsole material 102 on the lower surface of the sole frame 200. The areas of juncture between the protective component 204 and the lightweight midsole material 202 are highlighted in Figs. 2A - 2F along line 206. Also, the junction areas between a mid-foot support element 208 (e.g., similar to support element 108 of Figs. 1A - 1F) and the lightweight midsole material 202 and/ or protective component 204 are highlighted in Figs. 2A - 2F along line 210. The lower surface of protective member 204 also includes traction elements and the like, as well as some features described in more detail below with respect to Figs. 10A and 10B.
[061] Another example of the structure of the alternative sole 300 according to some examples of this invention is shown together with Figs. 3A and 3B. Like the other outsole structures 100, 200 described above, the outsole structure 300 includes a lightweight foam midsole material 302 coupled, eg, by adhesives or cements, with a protective component 304. The protective component 304, which may being made of a denser or more durable polymer foam and/or outsole material, provides at least a portion of the lower surface of the sole structure 300. The sole structure 300 of Figs. 3A and 3B may be generally similar in structure and function to the structure of the sole 200 shown in Figs. 2A - 2F, although other structures and functions are possible without departing from the invention. For the sake of brevity, similar parts between Figs 2A - 2F and those in Figs. 3A - 3B will not be described in detail in this specification. Instead, the following discussion will focus on the differences between the structures shown in Figs. 3A - 3B compared to those shown in Figs. 2A - 2F. As those skilled in the art can understand, parts not described in detail below with respect to Figs. 3A - 3B may have the same or similar structures and/or the same or similar features and/or options for those similar parts and structures described above with respect to Figs. 1A - 2F.
[062] In the exemplary sole structures 100, 200 described above, the corrugated structure runs uninterrupted around the entire heel area of the lightweight midsole components 102, 202. This is not a requirement. Instead, as shown in Figs. 3A and 3B, the back heel area of these exemplary lightweight midsole components 302 includes a cut or cut area 310 on its upper side. This cut area 310 may extend to any desired vertical distance on the midsole component 302 without departing from the invention. As illustrated in Fig. 3B, in this exemplary structure 300, cut area 310 extends downward through at least two (and optionally more) of the individual corrugated structures although other arrangements are possible without departing from the invention. The cut area 310 may also extend downwardly from 25% to 65% of a total vertical height (H) of the sole structure 300 (and/or midsole component 302) immediately adjacent to the cut areas 310. Also , while Figs. 3A and 3B show cut area 310 only in midsole component 302, cut area 310 could also be provided in protective component 304, especially for sole structures in which protective component 304 has a greater presence in the vertical dimension at the location of the cut area 310.
[063] The cut-out area 310 of this exemplary sole structure 300 is somewhat V-shaped so as to provide an open V-shaped area at the trailing edge of the midsole component 302. Other shapes for the cut-out area 310 are possible without from this invention, such as, U-shaped, rectangular or square, circular, star-shaped, logo-shaped, and/or any other desired configuration. This exemplary cut area 310 helps provide flexibility to the overall sole 300 structure, and particularly to the midsole component 302, in the direction from the lateral side to the midside. This can provide a more natural movement or feel as a user engages in walking or other activities such as running, jumping, or the like. Additional cut areas or the like may be provided at other locations around the structure of the sole 300 (i.e., not limited to the back heel area). For example, the cut areas 310 along the lateral and/or middle sides of the sole frame 300 (eg, in the toe area) can help provide and establish flex lines for the sole frames (optionally to improve the flexibility of the 300 sole structure to more closely match or support natural foot flexion tendencies).
[064] In the cut area 310 of this exemplary sole structure 300, the exposed edge of the foam midsole material 302 is covered by an edge element 312, e.g., a molded thermoplastic polyurethane member, another plastic member, etc. This 312 edge element, formed like a heel clip, helps protect the exposed edges of the 302 foam midsole material and helps provide interesting aesthetic or design opportunities. Edge elements 312 of this type also allow a person to change the shape of the cut area 310, if desired. Edge elements 312, when present, may be secured to the foam midsole component 302 and/or the other portion of the overall sole structure 300 and/or shoe structure in any desired manner without departing from the invention. As more specific examples, these components can be coupled together using adhesives or cements, mechanical connectors, or the like. Edge element 312 can also be used to affect the flexural or stiffness characteristics of the structure of the sole 300.
[065] As further shown in Fig. 3B, some of the various wave areas of the foam midsole component 302 of this structure 300 have origin points 360 located at or near the edge of the cut area 310. While the individual waves are interrupted by cut area 310 may have their origin points 360 at the edge of cut area 310, in this illustrated exemplary sole structure 300, additional wave areas located below cut area 310 also have their origin points 360 located at the rear heel area. Alternatively, if desired, the lower wave areas could extend continuously around the uninterrupted back heel area (although optionally with change in size) without departing from the invention. Other wave configurations above and/or below cut area 310 can also be used without departing from this invention.
[066] While described above as a “cut” or “cut” area 312, this area 312 need not be provided in any part of the structure of the sole 300 by a cutting action. Rather, area 312 could be provided on the desired component(s) of sole structure 300 in any desired manner without departing from the invention, including through the use of a cutting action, e.g., by a laser, knife, blade , mold or other cutting system. Alternatively, area 312 could be formed directly into the component(s) of the sole structure (eg, components 302 and/or 304) during its manufacturing process, such as by being molded directly into the structure of the foam midsole component 302 and/or a protective component 304. Therefore, the term "cut area" as used herein in this context and/or for this type of component or structure should be interpreted to include an area of this type of structure independent of how the area is provided in the component.
[067] Figs. 3A and 3B also show that in this exemplary structure 300, some of the areas between the waves in the back heel area, adjacent to the cut area 310, have windows 362 that extend completely through the sidewall of the midsole member 302. In the illustrated example 300, windows 362 extend along the edges of waves located above and below them (as the waves taper to their point of origin 360), although other shapes for windows 362 can be used without departing from the invention . The windows 362 may affect the flexibility of the midsole component 302 in the rear heel area of this exemplary sole structure 300. More or less windows 362 can be provided in the sole structure 300 without departing from the invention, including more or less windows 362 on both sides of the cut area 310 (including windows 362 on one or both sides).
[068] The windows 362 can be provided in the desired component(s) of the sole structure 300 in any desired manner without departing from the invention, including through the use of a cutting action (eg, by a laser, knife, blade , mold or other cutting system), by integrally forming windows 362 directly into the sole frame component(s) (e.g., components 302 and/or 304) during their manufacturing process (such as by molding windows 362 directly into the interior of the structure of the foam midsole component 302 and/or a protective component 304), etc.
[069] While the sole structures 100, 200, 300 of Figs. 1A to 3B all show corrugated structures having three to five individual corrugated structures over various areas that are shaped relatively uniformly, this is not a requirement. As another example, Fig. 4 illustrates a portion of another exemplary sole component 400 in which the corrugated structure 402 includes three waves oriented in the vertical or top-down direction. The view of Fig. 4 shows a side side view of this exemplary wave structure 402, but a similar structure could be provided, for example, on the middle side of the sole component 400 and/or in the rear heel area of the sole component. 400. This exemplary wave structure 402 can be provided in the foam midsole component as illustrated in Fig. 4 (eg, similar to components 102, 202, and/or 302 discussed above), or it can be provided in the protective component , as polymeric foam protective component and/or components as components 104, 204, 304 discussed above in conjunction with Figs. 1A to 3B. Also, while only the heel area of the sole component 400 is shown in Fig. 4, those skilled in the art, given the benefit of this disclosure, will readily understand that a sole component for supporting an entire plantar surface of a wearer's foot ( or any portion thereof) could be provided without departing from this invention.
[070] The corrugated structure 402 of Fig. 4 is different from some of the other corrugated structures described above with respect to Figs. 1A - 3B in wave shape. More specifically, as shown in Fig. 4, the central wave 402b of this exemplary corrugated structure 402 is concave (or outwardly expanding) in both upward and downward directions. As shown in Fig. 4, the lower valley of the interstitial area 404a between the center wave 402b and the upper wave 402a curves in an upwardly concave direction so that the high point of that curve is in the center side heel area. Similarly, the lower valley of the interstitial area 404b between the central wave 402b and the lower wave 402c curves in a downward concave direction so that the low point of that curve is in the central side's heel area. Because of this configuration, the upper wave 402a is shaped to curve in an upward direction with a maximum point of the upper part of that curve located in the central area of the upper wave 402a in the arrangement shown in Fig. 4. Similarly, the similar wave 402c is shaped to curve in a downward direction with the lower minimum point of that curve located in the central area of the bottom wave 402c in the arrangement shown in Fig. 4. This gives the overall wave structure 402 a bit of a more bulbous shape in compared to at least some of the corrugated structures as shown in Figs. 1A to 3B.
[071] Notably, the wave construction 402 has smoother side walls (like the corrugated structures of Figs. 2A-3B) compared to the stepped side walls in the corrugated structure as shown in Figs. 1A-1F. Also, the wave construction of Figs. 2A-4 has other individual wave crests formed as sharp corners. Other structural options for these side walls and/or corners are possible, however, without departing from this invention.
[072] Figs. 5, 6, and 7 show side views of several different examples of footwear articles 550, 650, and 750 that include sole structures 500, 600, and 700 in accordance with other examples of this invention. Fig. 5 illustrates basketball shoe 650, Fig. 6 illustrates running shoe 650, and Fig. 7 illustrates diversified training shoe 750. Sole structures 500, 600, and 700 are coupled with uppers 552, 652, and 752, respectively, to provide general shoe structures 550, 650, and 750. Uppers 552, 652, and 752 can be engaged with their respective sole structures 500, 600, and 700 in any desired manner without from this invention, including in conventional ways as they are known and used in this art. As more specific examples, the uppers 552, 652, and 752 and the sole structures 500, 600, and 700 can be coupled together by adhesives or cement, by mechanical connectors, by stitching or stitching, and/or by other techniques of connection.
[073] In the additional description of the structures of shoes 500, 600, and 700 of Figs. 5-7, several exemplary tops features (including potential tops features 552, 652, and 752) will be described. This description includes examples of uppers features that can be included in footwear structures in accordance with at least some examples of this invention, including examples of uppers that can be coupled with the sole structures 100, 200, 300, and 400 of the Figs. 1A-4. Because the 500, 600, and 700 sole structures of Figs. 5-7 generally have similar structures, some differences between the 500, 600, and 700 sole structures will be described in conjunction with Figs. 5-7. Thereafter, more detailed construction features and parts of the 500, 600, and 700 outsole structures of Figs. 5-7 will be described in more detail in conjunction with Figs. 8A-8F.
[074] The upper parts 552, 652, and 752 for the article of shoe structures 550, 650, and 750 according to this invention may constitute one or more component part constructions that can be coupled together in any desired manner, including in conventional ways as they are known and used in the footwear art, including through the use of cements or adhesives, through the use of mechanical connectors, and/or through melting techniques (eg, melt bonding or melting a material hot melt, etc.). Non-limiting examples of some construction techniques will be described in more detail below.
[075] Tops 552, 652, 752 can be made from any desired materials and/or combinations of materials without departing from this invention. For example, the tops 552, 652, 752 may include a multi-layer construction, with the various layers covering all or some portion of the area of the total top. In some more specific examples, the tops 552, 652, 752 may include an intermediate weft layer covered and/or sandwiched in at least some areas by an inner fabric or textile layer (eg, for comfortable foot contact ) and an outer “skin” layer (eg, made of a thermoplastic polyurethane film, to provide better support in certain areas, to provide resistance to wear or abrasion in certain areas, to provide desired aesthetics, etc.) . None of the inner fabric or textile material layer, the mesh layer, and/or the fur layer need extend to cover an entire surface of the tops 552, 652, 752. Instead, the location(s) of the various layers can be selected to control the properties of the tops 552, 652, 752, eg by omitting the skin layer in certain areas to improve breathability, to improve flexibility, to provide a different aesthetic appearance (such as openings in the skin layer. skin to produce a “LOGO” or other design feature from the underlying weft material), etc. Also, as shown in the art, the uppers 552, 652, 752 can define an ankle opening, around which a foam or comfort-enhancing fabric ring can be provided, if desired. The bottom surface of the tops 552, 652, 752 may include an inner strobel member that connects the middle and side sides of the top material (eg, the strobel member can be sewn to the middle or side edges of the part. top) to thus close the upper parts 552, 652, 752. The sole structures 500, 600, 700 can be engaged with the upper parts 552, 652, 752 on these lower edges and the strobel, eg using cements or adhesives, sewing or stitching, mechanical connectors, etc.
[076] The multilayer upper construction can be produced in any desired manner without departing from this invention, including in conventional ways as are known and used in the footwear art. For example, if desired, the skin layer can be made of a "seamless" type material which can be adhered to the underlying weft layer (or other layer) using an adhesive or heat-molded material in a conventional manner, e.g. ., by the application of heat and/or pressure. As further examples, if desired, the skin layer may be engaged with the underlying weft layer (or other layer) by cements or adhesives and/or by stitched seams. As yet further examples, if desired, the tops 552, 652, 752 (or portions thereof) can be constructed by gluing multiple layers of materials using melting techniques, e.g., as described in US Patent Application Publication . No. 2011/0088282 and US Patent Application Publication. No. 2011/0088285, each of which is fully incorporated herein by reference.
[077] Tops 552, 652, 752 may include other support elements at desired locations, e.g. sandwiched between the outer skin layer and the underlying weft layer. For example, a heel can be provided in the heel area to provide more support for the user's heel. The heel, where present, may be made of a thin, rigid plastic material such as PEBAX, TPU, or other polymeric material, and may include one or more openings (eg, to control flexibility, breathability, bearing characteristics ; to reduce weight; etc.). If needed or desired, additional supports can be provided in other areas of the 550, 650, 750 shoe, such as in the forefoot or toe area (to provide protection and wear resistance, etc.), in the side area lateral near the fifth head of the metatarsal, etc.
[078] Other potential materials that can be used in uppers 552, 652, 752 in accordance with at least some examples of this invention include one or more of: synthetic leather, natural leather, textiles, any combination of these materials, and/or any combinations of these materials with any other materials described above. As another potential feature, if desired, at least some portions of the tops 552, 652, 752 can be formed by a knitting procedure. Optionally, at least a majority (or even all) of the tops 552, 652, 752 can be formed using knitting procedures in at least some examples of this invention. Fabricated textile components can be used to provide lightweight, breathable and comfortable upper constructions.
[079] Returning now to Fig. 5, additional details of this structure of the exemplary 550 shoe will be discovered. This structure of the exemplary 550 shoe is a basketball shoe. The upper 552 may have a construction like that of any conventional basketball shoe, including constructions made of leathers, multi-layer melt-bonded materials, or other materials and/or constructions as are known and used in the art. The structure of the sole 500 of this example has an overall appearance similar to the structure of the sole 100 shown in Figs. 1A to 1F as described in detail above, e.g., including a series of five stacked waves that extend continuously around the sole frame 500 from the area on the lateral side of the toe, around the back heel area, for the mid-toe area of the 500 soleframe. The five-wave construction of this exemplary 500 soleframe is well suited for a basketball shoe because it creates a slightly taller heel frame, as is common in modern basketball shoes.
[080] While similar in appearance to waves, however, the structure of the sole 500 of Fig. 5 differs considerably in construction from the structure of the sole 100 of Figs. 1A-1F. While the Detailed Construction Description of this sole structure 500 will be saved for the discussion of Figs. 8A-8F below, at this time it is adequate to say that the exposed rear portion 504 of the sole frame 500 constitutes a protective element that at least partially secures and contains a portion of the midsole component 502. The rear protective component 504 can be made to from materials such as the various protective components 104, 204, 304 described above (eg, including a polymeric foam material with one or more corrugated structures formed on its outer wall edge). The front portion 502 of the outsole structure 500 in this example constitutes an exposed portion of a lightweight foam midsole material 502, which may be similar to the lightweight midsole components 102, 202, 302 as described above (including the same or similar materials). While midsole components 502 may still extend to support all or substantially all of the plantar surface of a user's foot, in this illustrated example structure 500, at least some, and optionally a majority, of the lightweight midsole components 502 is contained within the protective component 504. In this way, at the back of the shoe frame 550, the protective component 504 acts as a box or carrier for the lightweight foam component 502. The foam midsole component 502 extends outwardly of the front (open) end of protective member 504, as will be described in more detail below.
[081] Going now to Fig. 6, the additional details of this structure of the exemplary 650 shoe will be described. This structure of the exemplary 650 shoe is a running shoe. The upper 652 may have a construction like that of any conventional running shoe, including constructions made from multi-layer melt glued materials, textiles, knits, knitted materials, or other materials and/or constructions as are known. and used in the art. The structure of the sole 600 of this example has an overall appearance similar to the structure of the sole 200 shown in Figs. 2A to 2F as described in detail above, eg including a first series of stacked waves 610 extending around the rear heel area of the sole frame 600 and a zigzag front series of waves 612 extending forwardly from the heel area toward the midfoot and toe point areas of the sole frame 600. The front wave series 612 originate in the interstitial areas between the waves of the rear heel wave series 610. The upper wave The front heel series of waves 612 originates above the top wave of the rear heel wave series 610. The rear heel series of waves 610 ends at the heel to the midfoot area, eg, in the interstitial areas between or along of the individual waves of the front series of waves 612. While Fig. 6 shows only the side view, the middle side view of this shoe structure 650 may have a similar interstitial wave configuration.
[082] The structure of the sole 600 for this exemplary 650 running shoe is a little shorter and with a lower profile than the structure of the sole 200 of Figs. 2A-2F and the sole structure 500 of Fig. 5. Notably, the sole structure 600 includes three vertically stacked waves 610 in the rear heel area (instead of the five waves shown in Figs. 2A-2F) and three front waves vertically stacked 612 zigzag from heel curls 610. While not necessary, this reduced number of curls provides somewhat less vertical height in the heel area of the 600 sole frame.
[083] Also, like the outsole structure 500 of Fig. 5, the exposed rear portion 604 of the outsole structure 600 constitutes a protective element that at least partially secures and contains a portion of a lightweight foam midsole component 602. Rear protective component 604 can be made from materials such as the various protective components 104, 204, 304 described above (e.g., including a polymeric foam material with one or more corrugated structures formed on its outer wall edge) . The front portion 602 of the sole structure 600 in this example constitutes an exposed portion of a lightweight foam midsole material 602, which may be similar to the lightweight midsole components 102, 202, 302 as described above (including the same or similar materials). While midsole component 602 may still extend to support all or substantially all of the plantar surface of a wearer's foot, in this exemplary structure 600, at least some, and optionally a majority, of the lightweight midsole components 602 are contained within. of protective component 604. Thus, on the back of the shoe frame 650, protective component 604 acts as a box or carrier for lightweight foam midsole component 602. Foam midsole component 602 extends to outside the front (open) end of protective member 604 as will be described in more detail below.
[084] With respect to the vertical direction shown in Fig. 6 (eg, with the shoe 650 oriented on a horizontal contact surface), the heel and/or midfoot area includes interlaced waves from a series of waves of the back heel 610 and the front series of waves 612. In other words, as one moves in the vertical direction in at least some portions of the heel and/or midfoot area of the sole frame 600 (eg, shown along line 614), it will find the individual wave surfaces of the front series of waves 612 located between the individual wave surfaces of the rear heel series of waves 610. These stacked and/or intertwined wave series provide added support in this area of the heel /middle of the foot and provide good support for a running shoe sole.
[085] Fig. 7 illustrates a training shoe 750. The upper 752 may have a construction like that of any conventional training shoe, including constructions made from melt bonded materials, textiles, knits, knitted materials, or other materials and/or constructions as are known and used in the art. The structure of the sole 700 in this example has an interstitial wave configuration as will be described in more detail below. Like the sole frame 500 of Fig. 5, the exposed rear portion 704 of the sole frame 700 constitutes a protective element that at least partially secures and contains a portion of the midsole component 702. The rear protective component 704 can be made to from materials such as the various protective components 104, 204, 304 described above (eg, including a polymeric foam material with corrugated structures formed on its outer wall edge). The front portion 702 of the sole frame 700 in this example constitutes an exposed portion of a lightweight foam midsole material 702, which may be similar to the lightweight midsole components 102, 202, 302 as described above (including the same or similar materials). While midsole component 702 may still extend to support all or substantially all of the plantar surface of a wearer's foot, in this exemplary structure 700, at least some, and optionally a majority, of the lightweight midsole component 702 is contained within. of the protective component 704. In this way, on the back of the shoe frame 750, the protective component 704 acts as a box or carrier for the lightweight foam midsole component 702. The foam midsole component 702 extends to outside the front (open) end of protective member 704 as will be described in more detail below.
[086] In this exemplary 700 outsole structure, both the rear heel area of the protective component 704 and the front toe area of the foam midsole component 702 include a rippled structure stacked vertically in three (with the heel curls slightly deeper than the waves at the front). Several different types of support features are provided, however, in the midfoot to toe area, at least along the lateral side of the shoe 750 (although similar structures can be provided on the midfoot if desired). Moving in the vertical direction in Fig. 7, a first rib or support element 710 is provided along the underside of the lateral side of the sole frame 700 (in the foam midsole component 702 in this example). This first rib or support element 710 lies vertically downward from and proximate to a head support area of the fifth metatarsal head of the sole frame 700. A second rib or support element 712 is provided somewhat further back and above the first rib or support element 710. This second rib or support element 712 bridges the junction between the foam midsole component 702 and the protective component 704 in this exemplary structure 700 and peaks midway through the is and region of the arch of the sole frame 700. The second rib or support element 712 may have a longer overall longitudinal dimension end-to-end than the first rib or support element 710. A third rib or support element 714 is provided a little further forward and above from the second rib or support element 712. At least a majority (and potentially all) of this third rib or support element 71 4 is formed in the foam midsole component 702. The third rib or support member 714 vertically overlaps the first rib or support member 710 and is located vertically downwardly from and near the fifth metatarsal head support area. of the sole structure 700. This third rib or support element 714 may have a shorter longitudinal dimension (end-to-end) than the first rib or support element 710. A fourth rib or support element 716 is provided. slightly further behind and above the third rib or support element 714. This fourth rib or support element 716 also bridges the junction between the foam midsole component 702 and the protective component 704, but a majority of this is located in the midsole component 702 and to the front of the second rib or support element 712. A fifth rib or support element 718 is provided a little further afield. is forward and above from fourth rib or support member 716. At least a majority (and potentially all) of this fifth rib or support member 718 is formed in foam midsole component 702. strut 718 vertically overlaps first rib or support member 710 and third rib or support member 714, and is located proximate the head support area of the fifth metatarsal head of sole frame 700. Fifth rib or support member 718 may have a shorter longitudinal dimension than the first rib or support member 710 and/or the third rib or support member 714.
[087] Thus, the first rib or support element 710, second rib or support element 712, third rib or support element 714, fourth rib or support element 716, and fifth rib or support element 718 produce a discontinuity in the corrugated structures between the corrugated structures in the back heel protective component 704 and the foam front midsole component 702. These support ribs or elements 710, 712, 714, 716, and/or 718 provide additional support for the midsole areas of the lateral foot and/or toe of this sole structure 700, eg in an area near the fifth head of the metatarsal of the user's foot. This provides additional support for the user during training activities such as when pushing the outside of the foot, eg when performing a sharp turn or cutting action.
[088] While other specific structures are possible, in this illustrated example, the rib or support elements 710, 712, 714, 716, 718 are molded as structures such as raised pyramids that extend outward from the side surface of the sole structure 700. These ribs or support elements 710, 712, 714, 716, 718 may be oriented somewhat like the interlocking corrugated structures that are shown in the various other figures described above. More specifically, as shown in Fig. 7, these ribs or support elements 712 and 716 originate in the interstitial areas between the ribs or support elements 710, 714, and 718. These ribs or support elements 710, 712, 714, 716, 718 may also originate in the interstitial areas between the waves located in front of and/or behind the rib or support member. Notably, the outwardly extending peaks of the ribs or support elements 712, 716, and 718 substantially align in a backward direction from the front to the upper bottom. Also, the outwardly extending peaks of ribs or support elements 710, 714, and 718 substantially align in the vertical direction from top to bottom.
[089] The rib structures or support element of Fig. 7 are merely examples of structures to provide lateral and/or middle side support (and/or to change or control ground support features 700). Other altering support configurations, including different numbers of ribs, different arrangements of ribs, different rib shapes, and/or different relative orientation of ribs with respect to one another can be used without departing from this invention. Also, if desired, simple spans between adjacent corrugated structures could be provided, e.g., to alter a support or feel in the spans. "Spans" can include actual spacings in foam material or smooth foam material between corrugated structures.
[090] An exemplary construction of the 500, 600, and 700 sole frames of Figs. 5 to 7 is described in more detail in conjunction with Figs. 8A to 8F. Figure 8A shows a perspective view of an exemplary sole structure 800 including a rear protective component 804 and a foam midsole component 802 that extends forward and outward from the free end of protective component 804. Figure 8A shows the protective component 804 and the foam component 802 that fit together, but before being attached to each other, for example, using adhesives or cements. Fig. 8B shows bottom views of these two parts apart from each other, and Fig. 8C shows top views of these two parts apart from each other. As can be seen from these figures, the protective component 804 acts as a box or carrier that contains the rear of the foam midsole component 802. The foam midsole component 802 has an upper support surface 802a for supporting all or substantially all of the plantar surface of a user's foot (although if desired, the protective component 804 could also provide a surface to directly support at least some portions of the plantar surface of a user's foot). In addition to extending outwardly from the front, free end of the protective component 804, the foam midsole component 802 is exposed to a heel opening 806 defined in the lower surface of the protective component 804. Providing this bottom opening 806 can both reduce the weight and allow one person to control and change the flexibility characteristics of the overall 800 sole frame.
[091] In this exemplary structure 800, the foam midsole component 802 can be made from any desired foam material (or combinations of foam materials) without departing from this invention, including lightweight foam materials of the types described above in together with components 102, 202, 302. Optionally, if desired, the foam midsole component 802 can include one or more fluid filled bladders, mechanical shock absorbing structures, and/or other structures to provide force attenuation of impact embedded or included in it. In this illustrated example, however, the foam midsole component 802 constitutes a single, solid piece of foam material, preferably one of the lighter and/or less dense foam materials described above.
[092] The protective component 804 of this illustrated exemplary sole structure 800 may also constitute a polymeric foam material, including conventional polymeric foam materials as are known and used as midsole materials in the footwear art. As more specific examples, the protective component 804 can be made from polyurethane foam, ethylvinylacetate ("EVA") foams, phylon, or other known foams or midsole materials. In some exemplary structures in accordance with this invention, the polymeric foam material used for the 804 protective component will be a heavier, denser, and/or more durable foam material (eg, more wear resistant, more abrasion resistant, etc.) than the foam material used in the 802 foam midsole component.
[093] As further shown in Figs. 8A-8C, the polymeric foam material of protective component 804 can include corrugated structures formed around at least portion(s) of this perimeter edge. More specifically, Figs. 8A-8C show that the protective component 804 may constitute an outer structure including the corrugated structure (such as those of Figs. 5-7), the outer structure including: a sidewall 804a; a middle sidewall 804b; a back heel wall 804c connecting the middle side wall 804b and the side wall 804a; and bottom wall 804d connecting middle side wall 804b, side wall 804a, and back heel wall 804c. In at least some examples of this invention, the corrugated structure of the polymeric foam material of protective component 804 will extend continuously around an outer surface of at least a portion of sidewall 804a, rear heel wall 804c, and at least one middle side wall portion 804b. The corrugated structure of the polymeric foam material of protective component 804 may also include interwoven waves, support ribs or elements, vertical ribs, spans, and/or any of the other corrugated structures, features, and/or options described above.
[094] Figs. 8A-8C further show that at least a heel portion of the foam midsole component 802 is received in a space defined between a side wall 804a, the middle side wall 804b, the back heel wall 804c, and the bottom wall 804d of the protective member 804. One toe end of the foam midsole member 802 extends beyond the front end of side wall 804a and the front end of middle side wall 804b in this exemplary structure 800. This toe end of the foam midsole component 802 may be at least partially exposed in the finished outsole structure 800.
[095] As described above at least with respect to Fig. 7, both the outer side edge surface of the protective component 804 and the outer side edge surface of the foam midsole component 802 may include corrugated structures. For example, the corrugated structure of the 804 protective component may extend (continuously or discontinuously (eg, due to interwoven waves, other supports, and/or other features)) around a side-to-rear-to-heel side. middle side of the sole structure. Additionally or alternatively, the foam midsole component 802 may include the corrugated structure that extends around an area of the front toe of the outsole structure 800. In this specific example illustrated, the corrugated structure of the foam midsole component 802 includes three outer wave protrusions connected by the two interstitial wave areas.
[096] When both components 802 and 804 have corrugated structures, the corrugated structure of the foam midsole component 802 may or may not extend continuously with the corrugated structure of the protective component 804. These corrugated structures may be disrupted, e.g., by ribs or other support elements, by interstitial waves, by gaps in the sole structure, by smooth foam material, by external plastic or composite supports, by transition areas, or the like, without departing from the invention. Such "breaks" in corrugated structures can be provided at any desired locations, such as a lateral toe area of the sole frame and a mid toe area of the sole frame (eg, to provide locations that support flexion natural movement), in a lateral toe area of the sole frame (eg, to provide additional support for cutting or turning actions), and/or at other desired locations (eg, to provide support and/or or desired flexibility, including characteristics of natural movement flexibility).
[097] The undersurfaces of either or both the foam midsole component 802 and/or the protective component 804 can be provided with additional components. For example, for at least some portions of the 800 sole structure that will come into contact with the ground in use, abrasion resistant or wear resistant material may be applied to at least portions of the lower surfaces of these components in order to improve their strength. wear and tear and durability features. Fig. 8D illustrates exemplary outsole components 820 that may be applied to the undersurface of protective member 804, optionally, in receptacles 822 formed (e.g., molded or cut) in the heel area of protective member 804. Fig. 8E illustrates exemplary outsole components 824 that can be applied to the undersurface of the foam midsole component 802, optionally, in the receptacles or other shaped areas (e.g., molded or cut) in the toe area (area 826) of the component of 802 foam midsole. Fig. 8F illustrates these parts and how they fit together. These outsole components 820 and 824 can be made from any desired outsole material (or outsole material combinations) without departing from this invention, including rubbers, thermoplastic polyurethanes, and the like. Additionally or alternatively, one or more of the outsole components 820, 824 may constitute latch structures or receptacles for receiving detachable latch structures.
[098] Fig. 9 provides an expanded view of another exemplary sole structure 900 according to some examples of this invention. In this sole 900 structure, a lightweight foam midsole component 902 (eg, of the types described above) includes a support surface 902a to support all or substantially all of the plantar surface of a wearer's foot. A protective foam component 904 (optionally including any desired type of corrugated structures) extends around at least the sides of the midsole component 902 and acts as a box or carrier for that portion of the foam midsole component 902 that it contains (from the midfoot or lateral toe area, around the back heel area, to the midfoot or toe midfoot area in this example). A plurality of outsole protective components 906a, 906b, 906c, and 906d are provided to protect various areas of the bottom of the foam midsole component 902 (and/or the bottom of the protective component 904, the protective component 904 must be exposed on the lower outer surface of the sole frame 900). In this illustrated example, outsole component 906a protects one side of the heel of the foam midsole component 902 (and/or protective component 904), outsole component 906b protects the back heel area of the midsole component from foam 902 (and/or protective component 904), and outsole component 906c protects the other side of the heel of foam midsole component 902 (and/or protective component 904). A relatively large outsole protective component 906d in the toe area covers much, if not all, of the toe-bottom area of the foam midsole component 902 (and/or the protective component 904). These various components can be coupled together in any desired manner, for example by cements or adhesives, by mechanical connectors, or any other manner as shown and used in the art. These components can be made, for example, from any of the materials described above for the corresponding parts. Also, any of the individual components shown or described above in Fig. 9 can be made from one or more separate parts without departing from the invention.
[099] While Figs. 5-9 show sole structures in which the lightweight midsole components are at least partially covered by a protective component in the heel and/or midfoot areas (and which extends outward to be exposed in the toe area. sole structure), other configurations are possible without departing from the invention. For example, if desired, the exposed portions of the lightweight midsole components and the protective component could essentially end up as "slippers" in the structures of Figs. 5-9 so that the lightweight midsole components are covered by the protective component in the toe and/or midfoot areas (and extends outward to be exposed in the heel area of the sole frame). Modifications to the sizes, shapes, and/or joint areas between the lightweight midsole components and the protective component can also be varied widely without departing from the invention.
[0100] Figs. 10A and 10B show additional features that can be included in the sole structures in accordance with at least some examples of this invention. Fig. 10A shows the lower surface 1002a of a lightweight midsole component 1002 such as those described in detail above. The lower surface 1002a of this exemplary lightweight midsole component 1002 includes a plurality of outwardly extending or "bulb" areas at various locations of the midsole component 1002. A bulbous area 1004a is provided in the rear heel area of the midsole component 1002 and provides additional attenuation of impact force and/or a comfortable, soft feel, eg, for when the user steps or jumps. Additional bulbous areas are provided in the toe area of the sole frame 1000. More specifically, the bulbous area 1004b is provided, eg, under the fifth metatarsal head region on the lateral side of the midsole component 1002. A third bulbous region 1004c is located somewhat forwardly centered and median to a center of the bulbous area 1004b (eg, on the lateral side located under the head support area of the first metatarsal of the sole (ie, below the head area of the metatarsal of the big toe)). A fourth bulbous region 1004d is located opposite the third bulbous region 1004c (eg, on the lateral side located under a thumb and/or adjacent finger).
[0101] The bulbous areas 1004a-1004d in this exemplary structure 1002 are arranged to provide additional impact force attenuation and/or a comfortable, soft feel under the user's foot during certain activities such as running (or walking), landing of a step or leap, a leap of a leap, etc. During a typical stride cycle, a runner lands one step toward the side of the heel of the foot. Bulbous area 1004a is provided in the back heel area of this midsole component 1002 to provide additional impact force attenuation and/or a comfortable, soft feel at this moment of heel support. As the stride continues, the foot rolls forward and the edge of the side of the sole contacts the ground. Bulbous area 1004b is provided in the lateral side area (below the little toe) of this midsole component 1002 to provide additional attenuation of impact force and/or a comfortable, soft feel at this point in the stride cycle. As the foot continues to roll forward, it also begins to roll inward, towards the middle side, and eventually the runner takes off from the ground using the first area of the metatarsal head and/or big toe. (and possibly the adjacent finger). Bulbous areas 1004c and 1004d are provided in the mid-toe lateral area (below the ball of the foot and/or the big toe area) of this midsole component 1002 to provide additional attenuation of impact force and/or a comfortable feel , soft at these moments in the past cycle.
[0102] Fig. 10B shows an illustration of the lower surface 1000a of a sole structure 1000 that incorporates a midsole component 1002 of the type described above with respect to Fig. 10A included herein. As shown in this figure, the underside of the 1000 outsole frame includes traction elements and/or other features that are the basis of bulbous areas 1004a-1004d (eg, formed as part of a thin web-type protective component as will be described in more detail below). The bulbous nature of the 1000 sole structure at the various locations and the foam material above those locations help to provide good impact force attenuation in the bulbous areas 1004a-1004d. Additionally or alternatively, if the foam material of midsole component 1002 is sufficiently responsive, at least some of these bulbous areas 1004a-1004d can provide back energy to the foot (eg, applying a lifting force to the foot to the surface wearer's plantar as the impact force is reduced (as the foot lifts for the next step) and the foam midsole component 1002 returns to its original shape).
[0103] While four distinct bulbous areas are described and spaced apart in the manner described above with respect to Fig. 10A, this is not a requirement. Instead, any pattern of the bulbous areas, including more or less bulbous areas, can be provided in the midsole component without departing from this invention. Sole structures according to examples of this invention may include any number of bulbous areas, including no bulbous areas; one, two, or more bulbous areas (arranged in any desired way). Bulbous area(s) can be arranged to provide impact force attenuation, a soft feel, and/or bounce energy at any desired location(s), optionally depending on the intended use of the footwear. Bulbous areas of these types are also visible in the underside of the sole frame as shown in Figs. 2B-2F, 3A, 3B, and 7, and can be included in any desired sole structure.
[0104] Figs. 11A-11C show another exemplary basketball shoe 1150 that includes a sole structure 1100 in accordance with at least some examples of this invention. Fig. 11A is a view of the side side of the shoe 1150, Fig. 11B is a view of the middle side of the shoe 1150, and Fig. 11C is a view of the back heel of the shoe 1150. This shoe 1150 includes an upper 1152 having a multi-layer type, melt-glued top construction, although other constructions can be used without departing from this invention. The upper 1152 is coupled with a sole structure 1100 that includes features in accordance with at least some examples of this invention. Upper 1152 may be coupled with sole structure 1100 in any manner desired without departing from the invention, including in conventional ways as are known and used in the art. As more specific examples, the upper 1152 and sole frame 1100 may be coupled together, for example, by cements or adhesives, by mechanical connectors, by sewing or stitching, or the like.
[0105] The structure of the 1100 sole in this illustrated example includes three main component parts. The first part constitutes a lightweight (and low-density) 1102 midsole component, for example, of the various types described above. This 1102 foam midsole component can extend to support all or substantially all of the plantar surface of a wearer's foot. Portions of midsole component 1102 are exposed on the outer surface of shoe frame 1150 at various locations in this illustrated example, including: (a) along the side edge, at least in the midfoot area (see Fig. 11A); (b) in the front finger area (optionally at least on the lateral side; see Fig. 11A); (c) along all or substantially all of the middle side edge (see Fig. 11B); and (d) in a portion of the upper back heel area on the middle side (see Fig. 11C). This 1102 foam midsole component provides a soft, comfortable feel to the wearer's foot, as generally described above for other lightweight foam midsole structures.
[0106] The second part of this exemplary sole structure 1100 is a protective component 1104 that at least partially contains the foam midsole component 1102. The protective component 1104 of this illustrated example constitutes a protective component of the type of polymeric foam it may have. a denser or heavier foam construction than the foam material of the lightweight foam midsole component 1102. In this illustrated example, a portion of the protective component 1104 extends from an area of the middle of the side foot and/or heel of outsole frame 1100, around the back heel area of outsole frame 1100, and over a middle heel area outsole frame 1100. As best shown in Fig. 11C, the foam midsole component 1102 becomes extends outward from behind the protective component 1104 and is exposed on the outer surface of the shoe 1150 in the rear heel area of this sole frame 1100. Another portion of the protective component 1104 is provided in the lateral toe area of the shoe 1150, as shown in Fig. 11A. This side toe portion of the protective component 1104 may be integrally formed with the portion of the protective component 1104 in the rear heel area as a unitary, one-piece construction, or it may be a separate part. Another portion of the protective component 1104 of this example is provided in the extreme front toe area of the sole frame 1100, which extends around the front toe area from the middle side to the lateral side. This side toe portion of the front toe of protective member 1104 may be integrally formed with one or more of the other parts of protective member 1104 described above (as a unitary, one-piece construction), or may be a separate part.
[0107] The third part of this exemplary sole structure 1100 is an outsole element 1106, which may also function as a protective component, which is engaged with the underside of the foam midsole component 1102 and/or one or more of the polymeric foam protective components 1104. The outsole element 1106 of this exemplary sole structure 1100 covers a major portion of the lower surface of the shoe 1150. It may include traction elements such as grooves, ridges, protrusions, "fishbones" , and/or other tensile-enhancing components. One or more outsole protrusions, such as protrusion 1108, may cover and directly contact the bulbous area of a lower surface of the foam midsole component 1102 (such as the bulbous areas described above in conjunction with Fig. 10A to provide an area contact surface of outsole frame 1100. As also shown in Fig. 11B, this exemplary outsole component 1106 includes an aperture defined therethrough in which a lower surface of midsole member 1102 is exposed.
[0108] The outsole element 1106 may be made of a thin, highly flexible material that may have a base surface thickness (ie, a thickness of its base sheet or weft surface at locations not through a protrusion, a raised rib, a traction element, or the like) of less than 3 mm, and in some examples, a base thickness of less than 2 mm, less than 1.5 mm, or even less than 1 mm in some examples. This thin, flexible outsole element 1106 can be formed from synthetic rubber having a hardness and other properties similar to those of synthetic rubber compounds conventionally used for shoe outer soles. This thin outsole weft structure allows the outsole element 1106 to flex significantly between adjacent lugs 1108 and/or other structural components. In some outsole structures, outsole element portions 1106 may be formed from a rubber compound that is harder and more durable than other outsole element portions 1106. Higher durability rubber could be used , eg, on an impact pad located within the heel region and/or on the undersides of the straps located in certain other high pressure regions that typically wear out more quickly.
[0109] As shown in Fig. 11A, the protective component 1104 of this exemplary sole structure 1100 has a wave structure (with three outer wave crests) that appear similar, at least in some respects, to the wave structure described above in conjunction with Fig. 4. As shown in Fig. 11A, the center wave of protective element 1104 which extends around the heel area terminates between the wave crests of a two wave structure provided in the foam midsole component 1102 in the area of the middle of the lateral foot (at the end point 1110). A portion of another, front corrugated structure for the side toe protective component 1104 originates in the interstitial area between the two wave crests of the foam midsole component 1102 at point 1112. The corrugated structure of the foam midsole component of 1102 foam originates in the interstitial areas between the waves of protective elements 1104 located in front of and behind that wavy structure of the 1102 foam midsole component (see paragraphs 1114).
[0110] As shown in Fig. 11C, the three-wave structure on the side side of the protective component 1104 reduces down to a two-wave structure on the lower mid-heel side of the protective component 1104. foam 1102 emerges from under protective component 1104 in the back heel area, foam midsole component 1102 forms a two-wave structure that overlays the two-wave structure of protective component 1104 on the middle side of outsole structure 1100 Therefore, in this exemplary 1100 sole structure, the wavy structure that extends around the heel morphs from a three-wave structure on one side to a four-wave structure on the other side. On the middle side of outsole structure 1100, as shown in Fig. 11B, the wave structure of protective component 1104 terminates in the low, middle heel region of outsole structure 1100. The wave structure of foam midsole component 1102 extends additionally forward, and the upper outer ridge of this wavy structure extends forward in a somewhat wavy or curved manner. A shallower, independent corrugated structure runs around the front toe area along the side edge of the exposed foam midsole component 1104 and/or foam midsole component 1102, as shown in Figs. 11A and 11B.
[0111] While several of the exemplary outsole structures described above included: (a) a foam midsole component, eg, made of a lightweight foam material, and (b) another polymeric foam material as a protective element, optionally made of a heavier and denser polymeric foam material, it is not a requirement that a sole structure according to this invention have two different polymeric foam materials. Instead, as described above with respect to, for example, Figs. 1A-2F, if desired, a protective component in the form of an outsole component may be provided over at least a portion of the underside of the lighter, less dense foam midsole component without the need for another polymeric foam protective component. in the structure of the sole. Figs. 12A-12C illustrate another exemplary sole structure 1200 in which a lighter, less dense foam midsole component 1202 (e.g., of the types described above) is protected over at least portions of its lower surface with an outer sole component. 1206, without the inclusion of other polymeric foam backing material elsewhere in the structure of the 1200 sole.
[0112] Fig. 12A illustrates a side side view, Fig. 12B illustrates a middle side view, and Fig. 12C illustrates a bottom view of this exemplary sole structure 1200 and footwear article 1250 according to this example of the invention . This exemplary footwear article 1250 is a running shoe, and includes an upper 1252 constructed, for example, of any of the various materials described above. As more specific examples, the upper 1252 may be made, at least in part, of a fabric material, such as a knitted material, a knitted material, or the like. The upper 1252 may be coupled with the sole structure 1200 in any conventional manner, for example, using adhesives or cements.
[0113] While it is not necessary to have any corrugated structure, the side surface 1202a of the lightweight midsole component 1202 of this exemplary structure 1200 does not include several corrugated structures, although the overall corrugated structure of this 1200 outsole differs in some respects from the various others wavy structures described above. As shown in Fig. 12A, the heel area of this exemplary midsole component 1202 includes a three-layer corrugated structure 1210 that extends from the rear heel area around the lateral side of the shoe 1250. A layer corrugated structure double 1212 is provided in the mid-foot area of this midsole component 1202, and the two-layer corrugated structure 1212 is separated from the tri-layer corrugated structure of the back heel 1210 by a segment 1214 of the polymeric smooth foam material (the portion of the lightweight midsole component 1202) to thereby provide a gap in the corrugated structures on the lateral side of the shoe 1200. The series of two-layer midfoot waves 1212 ends in the midfoot/toe area of the sole frame 1200. Another smooth segment 1216 of the polymeric material (the lightweight midsole component portion 1202) produces a gap between the series of two-layer waves of the middle of the foot 1212 and a wave unique 1218 (or raised rib structure) that extends around the toe area of the 1250 shoe.
[0114] The raised single toe rib 1218 of this exemplary structure extends from the lateral side, around the front toe area, to the middle side of the 1250 shoe, as shown in Figs. 12A and 12B. As illustrated here, the 1218 single wave ends in the mid-toe area. After another short span 1220 with no waves (in which a smooth 1220 polymeric foam segment of this midsole component 1202 is provided), a series of two-layer waves 1222 begins and extends back through the toe area. The lower waves of the two-layer wave series 1222 terminate in the mid-foot area, in which another smooth segment 1224 of midsole material 1202 is provided. The upper wave of the series of two-layer waves 1222, however, extends continuously along the edge of the upper part of the midsole component 1202 at the junction between the midsole component 1202 and the upper 1252. After the segment smooth 1224, the wavy area of heel 1210 begins on the middle side of the sole frame 1200. Notably, the waves in the upper part of the 1222 toe wave series form the waves in the upper part of the 1210 back heel wave series.
[0115] The segments of the smooth polymeric foam material of the midsole component 1202, eg segments 1214, 1216, 1220, and 1224, provide areas that are somewhat stiffened in the vertical direction compared to the areas supported by the various wavy structures. In this exemplary structure 1200, notably a smooth span segment 1214 is provided in the heel lateral area of the sole frame 1200. This segment 1214 provides additional support for a runner's foot when supporting a stride during a running stride cycle. The smooth span segment 1216, also on the lateral side of the sole frame 1200, is located at or near the fifth metatarsal head area of the sole frame 1200. At this location, the somewhat hardened smooth segment 1216 provides additional support under the fifth area of the metatarsal head as the foot rolls forward as the stride cycle continues. Smooth span segment 1220 is located in the mid-toe or toe area of the 1200 sole frame and provides additional support for the user's toe area, eg, during the thrust phase of the stride cycle. The 1224 smooth span segment is provided in the arch area of the 1250 shoe and provides additional arch support for the wearer.
[0116] The wavy structure of the heel 1210 of this exemplary sole structure 1200 is interrupted in the lateral area of the middle heel by a series of angularly supported support ribs 1230. In this illustrated example, the support ribs 1230 are angled in a portion direction. upper back to lower front. Ribs 1230, however, may be oriented at any angle without departing from this invention, including at a vertical angle (90° from horizontal) when sole 1200 rests on a horizontal surface. As further examples, the ribs 1230 can be oriented at an angle within the range of 25° to 90° with respect to the horizontal direction (when the sole 1200 rests on a horizontal surface). Ribs 1230, when angled other than vertical, may be angled in the opposite direction from that shown in Fig. 12B, i.e., in a lower rear to upper front direction. Not all ribs in a series where more than one rib is present need to extend at the same angle as another rib (although all ribs can be parallel if desired).
[0117] These 1230 ribs provide additional support for the middle side of the foot during the stride cycle, for example, to prevent over-pronation during a stride cycle. While other arrangements are possible, in this illustrated exemplary sole structure 1200, the ribs of area 1230 extend from the upper corrugated element to the lower corrugated element of the series of waves of the back heel 1210. In this way, the ribs 1230 extend integrally from the upper and lower wave crests, and the ribs 1230 interrupt the center waves of the three-layer wave series 1210. Also, while the three-support rib elements 1230 are shown in Fig. 12B, one, two or more rib elements 1230 of this type could be provided as this type of mid-heel support without departing from the invention.
[0118] Also, the ribs 1230 of a series in an individual shoe 1250 may also have any desired shape without departing from the invention, including a triangular cross shape, a rounded cross shape, a flat or rectangular cross shape, etc. When more than one rib is present in a series in a 1200 sole frame, the multiple 1230 ribs in that series need not all have the same identical shape and/or even the same general shapes. Rather, the shapes of the rib elements 1230 can vary widely even in an individual shoe 1250 without departing from the invention.
[0119] Turning now to Fig. 12C, the structure of the outsole 1206 (or protective element) of this exemplary footwear article 1250 will be described in more detail. The outsole element 1206 can be engaged with the underside of the foam midsole component 1202, eg, using cements or adhesives. The outsole element 1206 of this exemplary sole structure 1200 covers a major portion of the lower surface of the footwear 1250. While it may include any desired types of traction elements and/or traction element configuration, in this illustrated example, the traction elements traction are primarily raised ribs (or shoulder straps) 1240 spaced around the underside of the sole frame 1200 in a generally matrix pattern. If desired, one or more outsole protrusions 1240 may cover and directly contact the bulbous area of the lower surface of the foam midsole component 1202 (such as the bulbous areas described above in conjunction with Fig. 10A) to provide the contact area soft sole structure 1200.
[0120] This outsole element 1206 is made of a thin, highly flexible material that may have a base surface thickness (ie, a thickness of its base sheet or weft surface at locations 1242 between protrusions 1240) of less 3 mm, and in some examples, a base sheet or weft surface thickness of less than 2 mm, less than 1.5 mm, or even less than 1 mm. While Fig. 12C shows protrusions 1240 as generally square or rectangular and substantially arranged in rows or columns (like a matrix), any desired protrusion shape(s) and/or protrusion arrangement(s) and/or spacing(s) ) can be provided on a sole structure without departing from the invention. The outsole element 1206 of this exemplary outsole structure 1202 may also have any of the structures, features, or characteristics of similar thin outsole components as described in Ped. of US Patent. No. 13/693,596 filed on December 4, 2012 and entitled “Article of Footwear” whose application is fully incorporated herein by reference.
[0121] This thin, flexible outersole element 1206 can be formed as a sheet-like material, eg, synthetic rubber having a hardness and other properties similar to those of synthetic rubber compounds conventionally used for outer soles of footwear. This thin outsole weft structure allows the outsole element 1206 to be very light and flex significantly between the adjacent protrusions 1242. In some outsole structures, the outsole element portions 1206 may be formed from one. rubber compound that is harder and more durable than other portions of the outsole element 1206, or the weft area of the outsole component 1242 can be made slightly thicker in some areas than others. Longer or thicker rubber could be used, eg, in an area of 1244 impact pad located within the heel region, on the underside of straps located in certain other high pressure regions that typically wear out more quickly, along the side edge of the 1206 outsole, etc. Fig. 12C further shows that this exemplary final weft type outsole structure 1206 is perforated in some locations (eg, see perforations 1246 in the toe and mid-toe areas in this illustrated example). Also, as further shown, the size of the overhang (eg, height, cross section dimensions, cross section shapes, etc.) may vary over different areas of the 1206 outsole structure.
[0122] The thin weft outsole member 1206 is engaged with the polymeric foam member to cover at least 60% of a surface area of a lower surface of the midsole component 1202, and in some examples at least 80% , at least 90%, or even at least 95% of this surface area. At least a majority of the weft base surface (a majority of the surface area between tensile elements) will have a thickness that is less than 2 mm thick, and in some examples less than 1.5 mm or even less than 1 mm thick. thickness. If desired, at least 75%, at least 85%, at least 90%, or even at least 95% of the web base surface (surface area between tensile elements) will have the thickness characteristics noted above.III. Conclusion
[0123] The present invention is disclosed above and in the accompanying drawings with reference to a variety of examples. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. The features of an exemplary framework may be provided, used, and/or exchanged in some of the other frameworks, even if that particular combination of frameworks and/resources is not described. A person skilled in the relevant art will recognize that various variations and modifications can be made to the structures described above without departing from the scope of the present invention as defined by the appended claims.

权利要求:
Claims (16)
[0001]
1. Article of footwear (1250) CHARACTERIZED by the fact that it comprises: an upper (1252); and a sole frame (1200) engaged with the upper (1252), the sole frame including: a polymeric foam member (1202) for supporting an entire plantar surface of a wearer's foot, wherein the foam member polymeric (1202) includes a foam material having a density less than 0.25 g/cm3, and a protective member (1206) engaged with the polymeric foam member (1202) to cover at least 60% of a surface area of a lower surface of the polymeric foam member (1202), wherein the protective member (1206) constitutes a web base surface with a plurality of traction elements (1240) extending downwardly from the web base surface, and wherein a thickness of a majority of the web base surface at locations between the plurality of traction elements (1240) is less than 2 mm thick; wherein an outer edge (1202a) of the polymeric foam member (1202) includes a first structure wavy (1210) that extends around a rear heel area of the sole frame; and wherein the outer edge (1202a) of the polymeric foam member (1202) includes a second corrugated structure (1212) that extends along one side of the sole structure, the first corrugated structure (1210) and the second corrugated structure ( 1212) being completely separated from each other by a flat area (1214) of the same polymeric foam member (1202).
[0002]
2. Article of footwear (1250), according to claim 1, CHARACTERIZED by the fact that the thickness of at least 75% of the base surface of the weft at locations between the plurality of traction elements (1240) is 1.5 mm or less.
[0003]
3. An article of footwear (1250) according to claim 1, CHARACTERIZED by the fact that at least a portion of the plurality of traction elements (1240) includes a plurality of protrusions arranged in a matrix pattern.
[0004]
4. An article of footwear (1250) according to claim 1, CHARACTERIZED by the fact that the lower surface of the polymeric foam member (1202) includes a first bulbous area (1004a-1004d) extending outwardly from a base level of the lower surface.
[0005]
5. An article of footwear (1250) according to claim 4, CHARACTERIZED by the fact that at least a portion of the plurality of traction elements (1240) includes at least one protrusion arranged to engage the first bulbous area (1004a-1004d ).
[0006]
6. An article of footwear (1250), according to claim 5, CHARACTERIZED by the fact that the first bulbous area (1004a) is in a heel area of the polymeric foam member (1202).
[0007]
7. An article of footwear (1250) according to claim 5, CHARACTERIZED by the fact that the first bulbous area (1004b) is in a head support area of the fifth metatarsal of the polymeric foam member (1202).
[0008]
8. An article of footwear (1250), according to claim 5, CHARACTERIZED by the fact that the first bulbous area (1004c) is in a support area of the head of the first metatarsal of the polymeric foam member (1202).
[0009]
9. An article of footwear (1250), according to claim 1, CHARACTERIZED by the fact that the first corrugated structure (1210) is at least partially interrupted by a support system (1230).
[0010]
10. An article of footwear (1250), according to claim 9, CHARACTERIZED by the fact that the support system (1230) includes at least one support rib integrally formed as part of the polymeric foam member (1202).
[0011]
11. An article of footwear (1250) according to claim 9, CHARACTERIZED by the fact that the support system (1230) includes a plurality of vertical or angled support ribs that extend between two non-adjacent waves of the first corrugated structure (1210).
[0012]
12. An article of footwear (1250), according to claim 11, CHARACTERIZED by the fact that the support system (1230) is located on a mid-heel side of the sole structure (1200).
[0013]
13. An article of footwear (1250), according to claim 1, CHARACTERIZED by the fact that the protective member (1206) covers at least 80% of the surface area of the lower surface of the polymeric foam member (1202).
[0014]
14. An article of footwear (1250) according to claim 1, CHARACTERIZED by the fact that at least a portion of the plurality of traction elements (1240) includes a plurality of protrusions arranged in a matrix pattern, and wherein the Weft base surface is perforated in the area of the forefoot between some of the protrusions.
[0015]
15. An article of footwear (1250), according to claim 1, CHARACTERIZED by the fact that the thickness of the base surface of the weft is not constant across the area of the protective element (1206).
[0016]
16. An article of footwear (1250) according to claim 1, CHARACTERIZED by the fact that at least a portion of the plurality of traction elements (1240) includes a plurality of protrusions arranged in a matrix pattern, and wherein at least but some of the bosses are dimensioned different from other bosses.

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同族专利:

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CA2902845A1|2014-09-25|

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WO2014151379A2|2014-09-25|

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AU2014235049A1|2015-10-15|

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MX2015012592A|2016-06-06|

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BR112015022776A8|2019-11-26|

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EP3449746A1|2019-03-06|

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HK1214481A1|2016-07-29|

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BR112015022776A2|2017-07-18|

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CA2902810C|2017-06-27|

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EP2967185A1|2016-01-20|

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WO2014152333A1|2014-09-25|

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EP2967184A1|2016-01-20|

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KR101889494B1|2018-08-20|

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WO2014151379A3|2014-11-13|

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CA2902845C|2017-07-11|

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HK1214097A1|2016-07-22|

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CN105050440A|2015-11-11|

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ZA201506095B|2016-11-30|

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CA2902810A1|2014-09-25|

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EP2967183A2|2016-01-20|

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AU2014235049B2|2016-10-20|

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CA2900541C|2017-06-27|

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AU2014239966B2|2016-11-03|

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CA2900541A1|2014-09-18|

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CN105101829A|2015-11-25|

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JP2016512160A|2016-04-25|

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MX2015012596A|2016-06-06|

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ZA201505652B|2016-11-30|

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AU2014229005A1|2015-08-27|

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JP2016512139A|2016-04-25|

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EP2967185B1|2018-07-25|

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KR20180021241A|2018-02-28|

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JP6339657B2|2018-06-06|

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HK1214482A1|2016-07-29|

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EP2967183B1|2018-12-26|

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KR20150132311A|2015-11-25|

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AU2014229005B2|2016-10-20|

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EP2967184B1|2018-12-26|

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MX363286B|2019-03-19|

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ZA201506094B|2016-11-30|

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MX2015012586A|2016-01-12|

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BR112015022776B1|2021-02-09|

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KR20150135351A|2015-12-02|

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CN105050441B|2017-10-10|

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JP2016511130A|2016-04-14|

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KR101833033B1|2018-02-27|

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CN105050440B|2017-06-23|

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CN105050441A|2015-11-11|

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BR112015022556A2|2017-07-18|

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EP3449746B1|2021-08-11|

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CN105101829B|2017-11-10|

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JP6430480B2|2018-11-28|

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WO2014144527A1|2014-09-18|

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AU2014239966A1|2015-09-10|

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KR20150130477A|2015-11-23|

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法律状态:
2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-04-22| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-04-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-06-15| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US13/838,051|US9504289B2|2013-03-15|2013-03-15|Sole structures and articles of footwear having a lightweight midsole member with protective elements|

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US13/837,967|US9510635B2|2013-03-15|2013-03-15|Sole structures and articles of footwear having a lightweight midsole member with protective elements|

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US13/835,715|US9301566B2|2013-03-15|2013-03-15|Sole structures and articles of footwear having a lightweight midsole member with protective elements|

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US13/837,967|2013-03-15|

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US13/838,051|2013-03-15|

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US13/835,715|2013-03-15|

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PCT/US2014/027221|WO2014152333A1|2013-03-15|2014-03-14|Sole structures and articles of footwear having lightweight midsole members with protective elements|

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